Article of footwear having an upper with a structured intermediate layer

ABSTRACT

An article of footwear and a method of manufacturing the footwear are disclosed. The footwear has an upper and a sole structure. The upper is secured to sole structure and the upper is formed from three layers: a first layer, a second layer, and a third layer. The second layer is formed from a polymer material and molded to the first layer, but the second layer may alternately be molded to the third layer. The third layer is joined with at least one of the first layer and the second layer such that the second layer is positioned between the first layer and the third layer.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to footwear. The invention concerns, moreparticularly, an article of footwear having a structured intermediatelayer extending through at least a portion of an upper of the footwear.

2. Description of Background Art

Conventional articles of athletic footwear generally include two primaryelements, an upper and a sole structure. The upper is secured to thesole structure and forms a void on the interior of the footwear forcomfortably and securely receiving a foot. The sole structure ispositioned between the upper and the ground, and the sole structure mayinclude a polymer foam midsole and an outsole. The midsole attenuatesground reaction forces (i.e., provides cushioning) as the footwearcontacts the ground, and may absorb energy, to lessen the forces exertedupon the foot and leg. The outsole forms a ground-engaging portion ofthe sole structure and is formed from a durable and wear-resistantmaterial. The sole structure may also include an insole that ispositioned within the void to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot,along the medial and lateral sides of the foot, and around the heel areaof the foot. In some articles of footwear, such as basketball footwearand hiking boots, the upper may extend upward and around the ankle toprovide support for the ankle. Access to the void on the interior of thefootwear is generally provided by an access opening. A lacing system isoften incorporated into the upper to selectively increase the size ofthe access opening and permit the wearer to modify certain dimensions ofthe upper, particularly girth, to accommodate feet with varyingdimensions. In addition, the upper may include a tongue that extendsunder the lacing system to enhance comfort of the footwear, and theupper may incorporate a heel counter to limit movement of the heel.

Various materials are conventionally utilized in manufacturing theupper. The upper of athletic footwear, for example, may be formed frommultiple material layers that include an exterior layer, an intermediatelayer, and an interior layer. The materials forming the exterior layerof the upper may be selected based upon the properties ofwear-resistance, flexibility, and air-permeability, for example. Withregard to the exterior layer, the toe area and the heel area may beformed of leather, synthetic leather, or a rubber material to impart arelatively high degree of wear-resistance. Leather, synthetic leather,and rubber materials may not exhibit the desired degree of flexibilityand air-permeability for various other areas of the exterior layer ofthe upper. Accordingly, the other areas of the exterior layer may beformed from a synthetic textile, for example. The exterior layer of theupper may be formed, therefore, from numerous material elements thateach impart different properties to the upper. The intermediate layer ofthe upper is conventionally formed from a lightweight and planar polymerfoam material that provides cushioning and enhances comfort. Similarly,the interior layer of the upper may be formed of a moisture-wickingtextile that removes perspiration from the area immediately surroundingthe foot. In some articles of athletic footwear, the various layers maybe joined with an adhesive, and stitching may be utilized to joinelements within a single layer or to reinforce specific areas of theupper.

SUMMARY OF THE INVENTION

The present invention is an article of footwear having an upper and asole structure. The upper is secured to sole structure and the upper isformed from a plurality of layers that may include: a first layer, asecond layer, and a third layer. In some embodiments of the invention,the first layer forms an exterior of the upper, and the third layerforms an interior of the upper. Alternately, the first layer may form aninterior of the upper, and the third layer may form an exterior of theupper. In other embodiments, a fourth layer may be placed adjacent thethird layer to form the interior of the upper. The second layer isformed from a polymer material, and the second layer is molded to thefirst layer. The third layer is joined with at least one of the firstlayer and the second layer such that the second layer is positionedbetween the first layer and the third layer.

The first layer may be a textile material such that the polymer materialof the second layer infiltrates the textile material of the first layerto secure the second layer to the first layer. The second layer may havea mesh structure, or the second layer may be a plurality of discrete orjoined polymer foam elements, for example. The third layer may be joinedwith at least one of the first layer and the second layer in astitchless manner, such as with an adhesive.

The sole structure includes a midsole and an outsole, and the firstlayer and the second layer may extend between the midsole and theoutsole. Depending upon the embodiment, at least one of the first layerand the second layer may also extend under the midsole, and the thirdlayer may extend over the midsole.

In another aspect of the invention, the sole structure includes amidsole. Edges of the third layer may be joined together to form variousseams. The insole effectively covers each of the seams, with theexception of a heel seam that may have a substantially verticalorientation and extends through a heel region of the footwear.Accordingly, the insole may provide a separation between each of theseams and the foot, with the exception of the heel seam.

Yet another aspect of the invention involves a method of manufacturingan article of footwear. The method includes providing a first layer ofan upper of the article of footwear, and molding a second layer of theupper to the first layer. A third layer of the upper is then joined withat least one of the first layer and the second layer such that thesecond layer is positioned between the first layer and the third layer.

The advantages and features of novelty characterizing the presentinvention are pointed out with particularity in the appended claims. Togain an improved understanding of the advantages and features ofnovelty, however, reference may be made to the following descriptivematter and accompanying drawings that describe and illustrate variousembodiments and concepts related to the invention.

DESCRIPTION OF THE DRAWINGS

The foregoing Summary of the Invention, as well as the followingDetailed Description of the Invention, will be better understood whenread in conjunction with the accompanying drawings.

FIG. 1 is a medial side elevational view of a first article of footwearin accordance with the present invention.

FIG. 2A is a first cross-sectional view of the first article offootwear, as defined by section line 2A-2A in FIG. 1.

FIG. 2B is a second cross-sectional view of the first article offootwear, as defined by section line 2B-2B in FIG. 1.

FIG. 3 is a top plan view of a material element that forms an interiorlayer of an upper of the first article of footwear.

FIG. 4 is a bottom plan view of the interior layer in an assembledconfiguration.

FIG. 5 is a rear elevational view of the interior layer in the assembledconfiguration.

FIG. 6 is a top plan view of a material element that forms an exteriorlayer of the upper of the first article of footwear.

FIG. 7 is a top plan view of an intermediate layer in combination withthe exterior layer.

FIG. 8 is a cross-sectional view that corresponds with thecross-sectional view of FIG. 2A and depicts another embodiment of thefirst article of footwear.

FIG. 9 a medial side elevational view of a second article of footwearhaving another upper in accordance with the present invention.

FIG. 10A is a first cross-sectional view of the second article offootwear, as defined by section line 10A-10A in FIG. 9.

FIG. 10B is a second cross-sectional view of the second article offootwear, as defined by section line 10B-10B in FIG. 9.

FIG. 11 is a top plan view of an intermediate layer in combination withan exterior layer.

DETAILED DESCRIPTION OF THE INVENTION

The following discussion and accompanying figures disclose two articlesof footwear in accordance with the present invention. Concepts relatedto the articles of footwear may be applied to a wide range of footwearstyles. For example, the concepts may be applied to athletic footwearstyles that include running shoes, basketball shoes, walking shoes,cross-training shoes, tennis shoes, soccer shoes, and football shoes,for example. In addition to athletic footwear, concepts related to thearticles of footwear may be applied to footwear styles that aregenerally considered to be non-athletic (e.g., dress shoes or workboots) or footwear serving a medical or rehabilitative purpose.Accordingly, one skilled in the relevant art will appreciate that theconcepts disclosed herein apply to a wide variety of footwear styles, inaddition to the specific style discussed in the following material anddepicted in the accompanying figures.

An article of footwear 10, in accordance with the present invention, isdepicted in FIGS. 1-2B as incorporating a sole structure 20 and an upper30. Sole structure 20 is secured to upper 30 and provides a durable,wear-resistant component that provides cushioning as footwear 10 impactsthe ground. Upper 30 is formed from an interior layer 40, anintermediate layer 50, and an exterior layer 60 that are joined in astitchless manner and positioned in an at least partially coextensiverelationship. That is, portions of layers 40, 50, and 60 are arranged ina laminar manner. As will be described in greater detail below,intermediate layer 50 is positioned between interior layer 40 andexterior layer 60, and intermediate layer 50 may exhibit a structuredconfiguration. In further embodiments of the invention additional layersmay be placed on either side of upper 30 such that the additional layersactually form the interior or exterior surface of upper 30.

Sole structure 20 exhibits a generally conventional configuration thatmay include a midsole 21 and an outsole 22. Midsole 21 is formed of apolymer foam material, such as ethylvinylacetate or polyurethane.Accordingly, midsole 21 attenuates ground reaction forces (i.e.,provides cushioning) and may absorb energy as sole structure 20 iscompressed between the foot and the ground. To enhance the forceattenuation and energy absorption characteristics of sole structure 20,midsole 21 may incorporate a fluid-filled bladder, as disclosed in U.S.Pat. Nos. 4,183,156 and 4,219,945 to Rudy, for example. Outsole 22exhibits a generally cupped configuration that extends over the lowersurface of midsole 21 and along side surfaces of midsole 21. Suitablematerials for outsole 22 are various rubber compounds, for example, thatprovide a durable, wear-resistant surface for engaging the ground.Outsole 22 may also incorporate a textured lower surface to enhance thetraction characteristics of footwear 10. In addition, footwear 10includes an insole 23, which is a relatively thin cushioning memberlocated within upper 30 and adjacent to a plantar surface of the footfor enhancing the comfort of footwear 10.

For purposes of reference, upper 30 includes a lateral region 31, anopposite medial region 32, an instep region 33, and a heel region 34.Regions 31-34 are not intended to demarcate precise areas of upper 30.Rather, regions 31-34 are intended to represent general areas of upper30 to aid in the following discussion. In addition to upper 30generally, references to the various regions 31-34 may also be appliedto each of layers 40, 50, and 60. Lateral region 31 extends through alongitudinal length of footwear 10 and is generally configured tocontact and cover a lateral side of the foot. Medial region 32 has asimilar configuration that generally corresponds with a medial side ofthe foot. Instep region 33 is positioned between lateral region 31 andmedial region 32, and instep region 33 extends over an instep area ofthe foot. Heel region 34 forms a rear portion of upper 30 and isgenerally configured to contact and cover a heel area of the foot. Inaddition, lateral region 31, medial region 32, instep region 33, andheel region 34 cooperatively define an access opening 35 for providingthe foot with access to the void within upper 30.

Layers 40, 50, and 60 of upper 30 effectively extend around midsole 21,as depicted in FIGS. 2A and 2B. More particularly, layers 40, 50, and 60are positioned in a coextensive relationship in regions 31-34. At apoint where layers 40, 50, and 60 approach midsole 21, however, interiorlayer 40 diverges from the coextensive relationship with intermediatelayer 50 and exterior layer 60 to extend over an upper surface ofmidsole 21. Intermediate layer 50 and exterior layer 60 continuedownward and extend between midsole 21 and outsole 22 to cover a lowersurface of midsole 21. That is, layers 40, 50, and 60 effectively wraparound each of the surfaces of midsole 21, with interior layer 40extending over the upper surface of midsole 21 and each of intermediatelayer 50 and exterior layer 60 extending between midsole 21 and outsole22 to cover a lower surface of midsole 21. In other embodiments of theinvention, each of layers 40, 50, and 60 may extend over the uppersurface of midsole 21, each of layers 40, 50, and 60 may extend betweenmidsole 21 and outsole 22 to cover a lower surface of midsole 21, orupper 30 may be joined in another manner to sole structure 20.Accordingly, the manner in which sole structure 20 and upper 30 arejoined may vary significantly within the scope of the present invention.

Interior layer 40 extends over the upper surface of midsole 21 andeffectively forms a substantial portion of the void within upper 30.More particularly, an exposed surface of interior layer 40 (i.e., thesurface opposite layers 50 and 60) defines the void within upper 30,which receives both insole 23 and the foot. In general, therefore,insole 23 is located within a lower portion of upper 30 and ispositioned in an area that will be adjacent to a plantar surface of thefoot for enhancing the comfort of footwear 10. As will be described ingreater detail below, edges of interior layer 40 are joined together toform seams, and insole 23 effectively covers the seams (except a heelseam) and separates the seams from the foot. That is, insole 23 islocated within the void formed by interior layer 40, and insole 23 ispositioned between the seams and the portion of the void that receivesthe foot. Accordingly, insole 23 provides a separation between thevarious seams and the foot, with the exception of the heel seam. In someembodiments of the present invention, additional layers of material maybe placed adjacent to interior layer 40 such that the additional layersactually form the interior surface of the void within upper 30.

Interior layer 40 and exterior layer 60 may be formed from a variety ofmaterials, including textile materials. A textile may be defined as anymanufacture from fibers, filaments, or yarns characterized byflexibility, fineness, and a high ratio of length to thickness. Textilesgenerally fall into two categories. The first category includes textilesproduced directly from webs of filaments or fibers by randominterlocking to construct non-woven fabrics and felts. The secondcategory includes textiles formed through a mechanical manipulation ofyarn, thereby producing a woven fabric, for example. The varioustechniques for mechanically manipulating yarn into a textile includeinterweaving, intertwining and twisting, and interlooping, whichincludes various knitting processes. Yarn is defined as an assemblyhaving a substantial length and relatively small cross-section that isformed of at least one filament, a plurality of filaments, or aplurality of fibers.

The structure of textile materials is generally porous and permitsmolten polymers, for example, to infiltrate the structure of interiorlayer 40 and exterior layer 60. In manufacturing upper 30, exteriorlayer 60, for example, is placed in a mold and a polymer material isinjected, poured, compressed, or otherwise placed into the mold. Thepolymer material infiltrates the textile material of exterior layer 60(i.e., the polymer material extends around the various filaments andfibers forming the yarn in the textile material) and, is permanentlybonded to exterior layer 60 upon cooling. That is, the polymer materialthat forms intermediate layer 50 may be molded to exterior layer 60. Inother embodiments of the invention, the polymer material formingintermediate layer 50 may be molded to interior layer 40. Suitablepolymer materials for intermediate layer 50 include silicone, variousrubbers, and polyurethane, for example. Although interior layer 40 andexterior layer 60 are generally discussed herein as being textilematerials, one or both of interior layer 40 and exterior layer 60 may beformed from any material to which intermediate layer 50 may be bonded.In addition, intermediate layer 50 may be formed from multiplematerials, or intermediate layer 50 may be formed from a single materialwith different densities in different portions of footwear 10.Accordingly, the properties of the materials forming intermediate layer50 may also vary to change the properties of intermediate layer 50 indifferent portions of footwear 10.

The molding process described above effectively joins intermediate layer50 to exterior layer 60. A portion of interior layer 40 is positionedadjacent to intermediate layer 50 and is also secured to intermediatelayer 50 and exterior layer 60. One suitable manner of joining interiorlayer 40 with intermediate layer 50 and exterior layer 60 is through anadhesive bonding process. An adhesive may be applied to interior layer40, and upon contact with intermediate layer 50 and exterior layer 60,the adhesive joins interior layer 40 to intermediate layer 50 andexterior layer 60. Alternately, the adhesive may be applied tointermediate layer 50 and exterior layer 60, or other joining techniquesmay be utilized (e.g., stitching or thermo-bonding).

The manner in which footwear 10 is manufactured will now be discussed indetail to provide a better understanding regarding the structure offootwear 10. With reference to FIG. 3, interior layer 40 is depicted asa single textile element that is formed to exhibit a unitary (i.e., onepiece) construction having a plurality of edges 41 a, 41 b, 42 a, 42 b,43 a, 43 b, 43 c, 43 d, 44 a, 44 b, 44 c, and 44 d. A plurality ofcorresponding seams 41′, 42′, 43′, and 44′ are respectively formed,therefore, when joining the edges of interior layer 40. Moreparticularly, seam 41′ extends along the longitudinal length of a lowerarea and is centrally-located with respect to lateral region 31 andmedial region 32. Seam 42′ is also centrally-located and extends in asubstantially vertical direction along heel region 34. A seam 43′ ispositioned in a forefoot area of upper 30 and joins a portion of thelower region with both of lateral region 31 and medial region 32. Inaddition, a seam 44′ is positioned in a rear area of upper 30 and joinsa portion of the lower region with heel region 34. As defined forpurposes of the present invention, the term unitary construction isintended to express a configuration wherein portions of a textileelement (i.e., layers 40 and 60) are not joined together by seams orother connections, as depicted with interior layer 40 in FIG. 3.Although the various edges 41 a-44 d are joined together to form seams41′-44′, the various portions of interior layer 40 are formed as anunitary (i.e., one piece) element without seams.

Interior layer 40 exhibits the general shape depicted in FIG. 3 prior tothe formation of seams 41′-44′. Following formation of seams 41′-44′,however, interior layer 40 exhibits the shape depicted in FIGS. 4 and 5.Seams 41′-44′ are formed by securing various edges of interior layertogether. More specifically, (1) seam 41′ is formed by securing edge 41a with edge 41 b; (2) seam 42′ is formed by securing edge 42 a with edge42 b; (3) a first portion of seam 43′ is formed by securing edge 43 awith edge 43 b (4) a second portion of seam 43′ is formed by securingedge 43 c with edge 43 d; (5) a first portion of seam 44′ is formed bysecuring edge 44 a with edge 44 b; and (6) a second portion of seam 44′is formed by securing edge 44 c with edge 44 d. Referring to FIGS. 3-5,the positions of regions 31-34 are identified to provide a frame ofreference relating to the various portions of interior layer 40. In someembodiments, the order of the various steps discussed herein may bealtered.

In order to join edges 41 a and 41 b to form seam 41′, interior layer 40is folded or otherwise overlapped such that edge 41 a is placed adjacentto edge 41 b. Stitching, an adhesive, or thermo-bonding, for example, isthen utilized to secure edge 41 a and edge 41 b. Textile element 40, asdepicted in FIG. 3, has a generally planar or otherwise flatconfiguration. Upon the formation of seam 41′, however, one portion oftextile element 40 generally overlaps the other portion of textileelement 40. The volume between the overlapping portions effectivelyforms the void within upper 30 for receiving the foot and insole 23.

The folding or overlapping of interior layer 40 to form seam 41′ placesedge 42 a adjacent to edge 42 b, which facilitates the formation of seam42′. With reference to FIG. 3, an edge 45 forms a generally u-shapedarea in a portion of textile element 40. Upon the joining of edges 42 aand 42 b to form seam 42′, the u-shaped area becomes an aperture ininterior layer 40 and effectively forms access opening 35. Each of edges43 a-43 d and edges 44 a-44 d are formed from a generally v-shaped areaof textile element 40. Accordingly, seams 43′ and 44′ may be formed byclosing the v-shaped areas and securing the various edges together.

Following the formation of each of seams 41′-44′, which may be performedaround a last having the general shape of a foot, the lower area ofinterior layer 40 is then secured to midsole 21 with an adhesive, forexample. Separately, exterior layer 60 may be formed, as depicted inFIG. 6. Exterior layer 60 exhibits the general shape of interior layer40, but has greater dimensions in order to wrap around the lower surfaceof midsole 21. Either prior to removing exterior layer 60 from a largertextile element or following removal, exterior layer 60 may be placedwithin a mold for purposes of forming intermediate layer 50. Asdiscussed above, exterior layer 60 is placed in a mold and a polymermaterial is injected into the mold. The polymer material infiltrates thetextile material of exterior layer 60 (i.e., the polymer materialextends around the various filaments and fibers forming the yarn in thetextile material) and, is permanently bonded to exterior layer 60 uponcooling. That is, the polymer material that forms intermediate layer 50may be molded to exterior layer 60, as depicted in FIG. 7.

The combination of intermediate layer 50 and exterior layer 60 is thenplaced over interior layer 40, which remains on the last, and portionsof intermediate layer 50 and exterior layer 60 extend around midsole 21to cover the lower surface of midsole 21. In order to join interiorlayer 40 to the combination of intermediate layer 50 and exterior layer60, an adhesive may be applied to interior layer 40 prior to placing thecombination of intermediate layer 50 and exterior layer 60 over interiorlayer 40. Alternately, the adhesive may be applied to a surface of thecombination of intermediate layer 50 and exterior layer 60. As discussedabove, other methods, such as stitching and thermo-bonding, may also beutilized to join interior layer 40 to the combination of intermediatelayer 50 and exterior layer 60. Furthermore, layers 40, 50, and 60 maybe joined prior to the lasting process, or different orders for joininglayers 40, 50, and 60 may be utilized within the scope of the presentinvention.

The combination of intermediate layer 50 and exterior layer 60 exhibitthe general shape of interior layer 40, but have greater dimensions inorder to wrap around the lower surface of midsole 21. Given thesimilarities in shape between interior layer 40 and the combination ofintermediate layer 50 and exterior layer 60, seams that correspond inlocation with seams 41′-44′ may be formed in the combination ofintermediate layer 50 and exterior layer 60. That is, edges of thecombination of intermediate layer 50 and exterior layer 60 may be joinedin a manner that is analogous to the edges of interior layer 40.

Following the general procedure outlined above, outsole 22 may be bondedto portions of the combination of intermediate layer 50 and exteriorlayer 60 that extend around midsole 21. The last is then removed fromthe void formed by interior layer 40, and insole 23 is then positionedwithin a lower are of the void. In addition, various finishing steps,such as reinforcing access opening 35, may be performed to placefootwear 10 in a commercially-presentable state, thereby substantiallycompleting the manufacture of footwear 10.

Based upon the above discussion, footwear 10 is structured such thatupper 30 forms a void for receiving the foot and insole 23. Upper 30includes interior layer 40, intermediate layer 50, and exterior layer60, and intermediate layer 50 is formed from a polymer material that ismolded to exterior layer 60 (or may be molded to interior layer 40).Interior layer 40 is joined with at least one of intermediate layer 50and exterior layer 60 such that intermediate layer 50 is positionedbetween exterior layer 60 and interior layer 40. Sole structure 20secured to upper 30, and intermediate layer 50 and exterior layer 60extend between midsole 21 and outsole 22. In addition, interior layer 40extends over midsole 21. As discussed above, this manner of securingupper 30 to sole structure 20 provides one example of many suitablejoining configurations.

Edges of interior layer 40 are joined together to form various seams41′-44′, as discussed above. Insole 23 effectively covers each of seams41′, 43′, and 44′, but does not cover seam 42′, which is substantiallyvertical and extends through heel region 34. With the exception of seam42′, therefore, insole 23 separates each of seams 41′-44′ from the foot.That is, insole 23 is located within the void formed by interior layer40, and insole 23 is positioned between each of seams 41′, 43′, and 44′and the portion of the void that receives the foot. Accordingly, insole23 provides a separation between each of seams 41′-44′ and the foot,with the exception of the substantially vertical seam 42′ in heel region34.

Interior layer 40 forms an interior surface of the upper that definessubstantially all of the void. Exterior layer 60 and interior layer 40may be textile materials, and the polymer material of intermediate layer50 infiltrates the textile material of exterior layer 60 to secureintermediate layer 50 to exterior layer 60. In addition, interior layer40 is joined with at least one of intermediate layer 50 and exteriorlayer 60. In some embodiments, a stitchless manner of joining interiorlayer 40 to the combination of intermediate layer 50 and exterior layer60 is utilized. Accordingly, an adhesive or thermo-bonding is suitable.In some embodiments, however, stitching may be utilized to join interiorlayer 40 to the combination of intermediate layer 50 and exterior layer60.

Intermediate layer 50 may have a variety of configurations within thescope of the present invention. As depicted in the figures, intermediatelayer 50 has a mesh structure that forms a plurality of generallyrectangular openings. Alternately, intermediate layer 50 may have a meshstructure that forms round, triangular, hexagonal, trapezoidal, orirregularly-shaped openings. In some embodiments, intermediate layer 50may form a non-mesh structure. For example, the polymer material mayform strips that run vertically, horizontally, or diagonally betweeninterior layer 40 and exterior layer 60. The polymer material may alsobe limited to specific regions of upper 30. For example, the polymermaterial of intermediate layer 50 may be limited to heel region 34, ormay extend through instep region 33 to reinforce this area of upper 30.

An advantage of the mesh structure of intermediate layer 50 relates todirectional stretch-resistance in the plane of upper 30, and flexibilityin other directions. Effectively, the mesh structure limits the degreeof stretch in upper 30, but allows upper 30 to freely flex. In someembodiments, the dimensions of the mesh structure of intermediate layer50 may vary throughout upper 30. For example, the size of the openingsin the mesh structure may be varied depending upon the desired degree ofstretch in each area of upper 30. The thickness of the individualsegments of the mesh structure may also be varied to control the degreeof stretch in specific areas of upper 30. Intermediate layer 50 may alsobe utilized to provide structural elements in upper 30. For example,intermediate layer 50 may be utilized to form a heel counter in heelregion 34, or intermediate layer 50 may be utilized to reinforceapertures through which a shoelace is threaded. Intermediate layer 50 isdiscussed above as wrapping around the lower surface of midsole 21. Insome embodiments, however, intermediate layer 50 may wrap around midsole21 to a lesser degree, as depicted in FIG. 8 or intermediate layer 50may be limited to portions of upper 30 that are not associated with solestructure 20. Accordingly, the specific structure of intermediate layer50 may vary significantly within the scope of the present invention.Another advantage to the mesh structure of intermediate layer 50 relatesto aesthetics. For this reason, intermediate layer 50 may be molded orotherwise formed to exhibit any practical and aesthetically-pleasingstructure, whether having a mesh or non-mesh configuration.

An article of footwear 100, in accordance with the present invention, isdepicted in FIGS. 9-10B as incorporating a sole structure 120 and anupper 130. Sole structure 120 is secured upper 130 and provides adurable, wear-resistant component that provides cushioning as footwear100 impacts the ground. Upper 130 is formed from an interior layer 140,an intermediate layer 150, and an exterior layer 160 that are joined ina stitchless manner and are positioned in an at least partiallycoextensive relationship. As will be described in greater detail below,intermediate layer 150 is positioned between interior layer 140 andexterior layer 160, and intermediate layer 150 may exhibit a structuredconfiguration.

Sole structure 120 exhibits a generally conventional configuration thatincludes a midsole 121 and an outsole 122. Midsole 121 is formed of apolymer foam material, such as ethylvinylacetate or polyurethane.Accordingly, midsole 21 attenuates ground reaction forces (i.e., impartscushioning) and may absorb energy as sole structure 120 is compressedbetween the foot and the ground. Outsole 122 exhibits a generally cuppedconfiguration that extends over the lower surface of midsole 121 andalong side surfaces of midsole 121. Suitable materials for outsole 122are various rubber compounds, for example, that provide a durable,wear-resistant surface for engaging the ground. Outsole 122 may alsoincorporate a textured lower surface to enhance the tractioncharacteristics of footwear 100. In addition, footwear 100 includes aninsole 123, which is a relatively thin, cushioning member located withinupper 130 and adjacent to a plantar surface of the foot for enhancingthe comfort of footwear 100.

Layers 140, 150, and 160 of upper 130 effectively extend around midsole121, as depicted in FIGS. 10A and 10B. More particularly, interior layer140 diverges from a coextensive relationship with intermediate layer 150and exterior layer 160 to extend over an upper surface of midsole 121.Exterior layer 160 continues downward and extends between midsole 121and outsole 122 to cover a lower surface of midsole 121. In contrastwith footwear 10, therefore, intermediate layer 150 is not depicted asextending between midsole 121 and outsole 122. In other embodiments ofthe invention, each of layers 140, 150, and 160 may extend over theupper surface of midsole 121, each of layers 140, 150, and 160 mayextend between midsole 121 and outsole 122 to cover a lower surface ofmidsole 21, or upper 130 may be joined in another manner to solestructure 120. Accordingly, the manner in which sole structure 120 andupper 130 are joined may vary significantly within the scope of thepresent invention.

Interior layer 140 extends over the upper surface of midsole 121 andeffectively forms a substantial portion of the void within upper 130.More particularly, an exposed surface of interior layer 140 defines thevoid within upper 120, which receives both insole 123 and the foot. Ingeneral, therefore, insole 123 is located within a lower portion ofupper 130 and is positioned in an area that will be adjacent to aplantar surface of the foot for enhancing the comfort of footwear 100.Interior layer 140 exhibits a configuration that is substantiallysimilar to the configuration of interior layer 40, and edges of interiorlayer 140 are joined together to form seams in the same manner asinterior layer 40. As with footwear 10, insole 123 effectively coversthe seams in interior layer 140 (except for a substantially verticalheel seam) and separates the seams from the foot. That is, insole 123 islocated within the void formed by interior layer 140, and insole 123 ispositioned between the seams and the portion of the void that receivesthe foot. Accordingly, insole 123 provides a separation between theseams and the foot, with the exception of the heel seam.

Interior layer 140 and exterior layer 160 may be formed from any of thematerials discussed above with respect to footwear 10, including varioustextile materials. The structure of textile materials is generallyporous and permits molten polymers, for example, to infiltrate thestructure of interior layer 140 and exterior layer 160. In manufacturingupper 130, exterior layer 160, for example, is placed in a mold and apolymer material is injected into the mold. The polymer materialinfiltrates the textile material of exterior layer 160 (i.e., thepolymer material extends around the various filaments and fibers formingthe yarn in the textile material) and, is permanently bonded to exteriorlayer 160 upon cooling. That is, the polymer material that formsintermediate layer 150 may be molded to exterior layer 160. In otherembodiments of the invention, the polymer material forming intermediatelayer 150 may be molded to interior layer 140. Although interior layer140 and exterior layer 160 are generally discussed herein as beingtextile materials, one or both of interior layer 140 and exterior layer160 may be formed from any material to which intermediate layer 150 maybe bonded.

Suitable polymer materials for intermediate layer 150 include variouspolymer foams whether formed from thermo-plastic or thermoset polymermaterials. More particularly, intermediate layer 150 may be formed froma polyurethane foam, for example. In contrast with intermediate layer50, therefore, intermediate layer 150 is formed from a foamed polymermaterial. In addition, intermediate layer 150 may be formed frommultiple materials, or intermediate layer 150 may be formed from asingle material with different densities in different portions offootwear 100. Accordingly, the properties of the materials formingintermediate layer 150 may also vary to change the properties ofintermediate layer 150 in different portions of footwear 100. In placeof the foamed polymer material, intermediate layer 150 may also beformed from sheets of rubber or thermoplastic polyurethane, for example.

The molding process described above effectively joins intermediate layer150 to exterior layer 160. A portion of interior layer 140 is positionedadjacent to intermediate layer 150 and is also secured to intermediatelayer 150 and exterior layer 160. One suitable manner of joininginterior layer 140 with intermediate layer 150 and exterior layer 160 isthrough an adhesive bonding process. An adhesive may be applied tointerior layer 140, and upon contact with intermediate layer 150 andexterior layer 160, the adhesive joins interior layer 140 tointermediate layer 150 and exterior layer 160. Alternately, the adhesivemay be applied to intermediate layer 150 and exterior layer 160, orother joining techniques may be utilized (e.g., stitching orthermo-bonding).

Footwear 100 may be manufactured in a manner that is substantiallysimilar to the manufacturing method for footwear 10. Accordingly, theedges of interior element 140 may be joined around a last, and midsole121 may be bonded to a lower area of interior element 140. Exteriorlayer 160 may be formed and placed within a mold for purposes of formingintermediate layer 150. As discussed above, exterior layer 160 is placedin a mold and a polymer foam material is injected into the mold. Thepolymer foam material infiltrates the textile material of exterior layer160 (i.e., the polymer foam material extends around the variousfilaments and fibers forming the yarn in the textile material) and, ispermanently bonded to exterior layer 160 upon cooling. That is, thepolymer foam material that forms intermediate layer 150 may be molded toexterior layer 160.

The combination of intermediate layer 150 and exterior layer 160, asdepicted in FIG. 11, is then placed over interior layer 140, whichremains on the last, and portions of exterior layer 160 extend aroundmidsole 121 to cover the lower surface of midsole 121. In order to joininterior layer 140 to the combination of intermediate layer 150 andexterior layer 160, an adhesive may be applied to interior layer 140prior to placing the combination of intermediate layer 150 and exteriorlayer 160 over interior layer 140. As discussed above, other methods,such as stitching and thermo-bonding, may also be utilized to joininterior layer 140 to the combination of intermediate layer 150 andexterior layer 160.

Following the general procedure outlined above, outsole 122 may bebonded to portions of exterior layer 160 that extend around midsole 121.The last is then removed from the void formed by interior layer 140 andinsole 123 is positioned within the void. In addition, various finishingsteps may be performed to place footwear 100 in acommercially-presentable state, thereby substantially completing themanufacture of footwear 100.

Based upon the above discussion, footwear 100 is structured such thatupper 130 forms a void for receiving the foot and insole 123. Upper 120includes interior layer 140, intermediate layer 150, and exterior layer160, and intermediate layer 150 is formed from a polymer material andmolded to exterior layer 160 (or may be molded to interior layer 140).Interior layer 140 is joined with at least one of intermediate layer 150and exterior layer 160 such that intermediate layer 150 is positionedbetween exterior layer 160 and interior layer 140. Sole structure 120secured to upper 130, and exterior layer 160 extends between midsole 121and outsole 122. In addition, interior layer 140 extends over midsole121.

Intermediate layer 150 may have a variety of configurations within thescope of the present invention. In general, intermediate layer 150exhibits a non-planar configuration and is, therefore, a non-planar foammaterial. As depicted in the figures, intermediate layer 150 has theconfiguration of a plurality of discrete and disk-shaped protrusions.Alternately, intermediate layer 150 may have the configuration ofconnected protrusions. Intermediate layer 150 may also have a pluralityof other configurations within the scope of the present invention.

An advantage of the various polymer foam protrusions that formintermediate layer 150 relates to protection of the foot. Specific areasof the foot are more likely to be contacted by objects or otherindividuals during activities, such as athletic activities. Thelocations of the polymer foam protrusions may be selected, therefore, tocorrespond with these areas of the foot. In addition, the size, density,and thickness, for example, of the protrusions may be selected to impartvarying degrees of protection in these areas. Accordingly, theconfiguration of intermediate layer 150 may vary significantly to impartcushioning to selected areas of upper 130. Another advantage to thevarious polymer foam protrusions that form intermediate layer 150relates to aesthetics. For this reason, intermediate layer 150 may beformed to exhibit any practical and aesthetically-pleasing structure.

Although interior layers 40 and 140 are depicted in the figures anddiscussed in the above material as forming an interior of uppers 30 and130, respectively, other layers or elements of material may be placedadjacent to either of layers 40 and 140 in order to form the actualinterior of uppers 30 and 130. Similarly, although exterior layers 60and 160 are depicted in the figures and discussed in the above materialas forming an exterior of uppers 30 and 130, respectively, other layersor elements of material may be placed adjacent to either of layers 60and 160 in order to form the actual exterior of uppers 30 and 130.Accordingly, the use of the terms interior and exterior is intended toprovide a reference for better understanding of the informationpresented herein.

The present invention is disclosed above and in the accompanyingdrawings with reference to a variety of embodiments. The purpose servedby the disclosure, however, is to provide an example of the variousfeatures and concepts related to the invention, not to limit the scopeof the invention. One skilled in the relevant art will recognize thatnumerous variations and modifications may be made to the embodimentsdescribed above without departing from the scope of the presentinvention, as defined by the appended claims.

1. An article of footwear having an upper and a sole structure,including a midsole and an outsole, secured to the upper, the uppercomprising: a first layer of the upper; a second layer of the upperformed from a polymer material, the second layer being molded to thefirst layer and having different properties in different portions of theupper; a third layer of the upper joined with at least one of the firstlayer and the second layer such that the second layer is positionedbetween the first layer and the third layer; and wherein the third layerdiverges from the first and second in a bottom region of the upper toextend over a top surface of the midsole and the first and second layersextend over a lower surface of the midsole and extend over a top surfaceof the outsole, wherein at least one of the first and second layers arein contact with the outsole.
 2. The article of footwear recited in claim1, wherein the first layer is a textile material, and the polymermaterial of the second layer infiltrates the textile material of thefirst layer to secure the second layer to the first layer.
 3. Thearticle of footwear recited in claim 1, wherein the third layer isjoined with at least one of the first layer and the second layer in astitchless manner.
 4. The article of footwear recited in claim 1,wherein the third layer is adhesively-bonded to the first layer and thesecond layer.
 5. The article of footwear recited in claim 1, wherein thesecond layer has a mesh structure.
 6. The article of footwear recited inclaim 5, wherein the mesh structure is a silicone material.
 7. Thearticle of footwear recited in claim 1, wherein the first layer and thesecond layer extend between the midsole and the outsole.
 8. The articleof footwear recited in claim 1, wherein the third layer extends over themidsole and between the midsole and an insole.
 9. The article offootwear recited in claim 1, wherein the upper forms a void forreceiving at least one of a foot and an insole, and the third layerforms an interior surface of the upper that defines substantially all ofthe void.
 10. The article of footwear of claim 1, wherein the thirdlayer is joined with at least one of the first layer and the secondlayer along a side of the upper.
 11. The article of footwear of claim 1,wherein the second layer is formed of multiple materials to provide thedifferent properties in the different portions of the article offootwear.
 12. The article of footwear of claim 1, wherein the secondlayer is formed of a material having different densities in differentregions to provide the different properties in the different portions ofthe article of footwear.
 13. An article of footwear, comprising: anupper defining a void for receiving at least one of a foot and aninsole, the upper having a first layer, a second layer, and a thirdlayer, the second layer being formed from a polymer material and moldedto the first layer, the second layer having a mesh structure providingstretch resistance in the plane of the upper and flexibility in otherdirections and the third layer being joined with at least one of thefirst layer and the second layer such that the second layer ispositioned between the first layer and the third layer; and a solestructure secured to the upper, the sole structure including a midsoleand an outsole, at least one of the first layer and the second layerextending between the midsole and the outsole and at least one of thefirst layer and the second layer contacting the outsole, and the thirdlayer extending over the midsole.
 14. The article of footwear recited inclaim 13, wherein the third layer forms an interior surface of the upperthat defines substantially all of the void.
 15. The article of footwearrecited in claim 13, wherein the first layer and the third layer aretextile materials, and the polymer material of the second layerinfiltrates the textile material of the first layer to secure the secondlayer to the first layer.
 16. The article of footwear recited in claim13, wherein the third layer is joined with at least one of the firstlayer and the second layer in a stitchless manner.
 17. The article offootwear recited in claim 13, wherein the third layer isadhesively-bonded to the first layer and the second layer.
 18. Thearticle of footwear recited in claim 13, wherein the mesh structure is asilicone material.
 19. The article of footwear of claim 13, wherein thethird layer is joined with at least one of the first layer and thesecond layer along a side of the upper.
 20. The article of footwear ofclaim 13, wherein at least one dimension of the mesh structure variesthroughout the upper.
 21. The article of footwear of claim 20, wherein asize of one or more openings in the mesh structure varies throughout theupper.
 22. The article of footwear of claim 21, wherein the size of theone or more openings may be based on a desired degree of flexibility ina portion of the upper.
 23. The article of footwear of claim 20, whereina thickness of a segment of the mesh structure varies throughout theupper.
 24. An article of footwear, comprising: an upper defining a voidfor receiving at least one of a foot and an insole, the upper having afirst layer, a second layer, and a third layer, the second layer havinga mesh structure formed from a polymer material that is molded to thefirst layer and the second layer having different properties indifferent portions of the upper, and the third layer being joined withat least one of the first layer and the second layer such that thesecond layer is positioned between the first layer and the third layer;and a sole structure secured to the upper.
 25. The article of footwearrecited in claim 24, wherein the third layer forms an third surface ofthe upper that defines substantially all of the void.
 26. The article offootwear recited in claim 24, wherein the first layer and the thirdlayer are a textile material, and the polymer material of the secondlayer infiltrates the textile material of the first layer to secure thesecond layer to the first layer.
 27. The article of footwear of claim24, wherein the third layer is joined with at least one of the firstlayer and the second layer along a side of the upper.
 28. The article offootwear of claim 24, wherein the second layer is formed of multiplematerials to provide the different properties in the different portionsof the article of footwear.
 29. The article of footwear of claim 24,wherein the second layer is formed of a material having differentdensities in different regions to provide the different properties inthe different portions of the article of footwear.
 30. An article offootwear, comprising: an upper defining a void, the upper having a firstlayer, a second layer, the second layer having a mesh structureproviding stretch resistance in the plane of the upper and flexibilityin other directions, wherein at least one dimension of the meshstructure varies throughout the upper, and a third layer, the thirdlayer being joined with at least one of the first layer and the secondlayer such that the second layer is positioned between the first layerand the third layer; and a sole structure secured to the upper, the solestructure including an insole positioned with the void, the third layerforming a third surface of the upper that defines substantially all ofthe void, edges of the third layer being joined together to form seams,the insole being positioned between: each of the seams except asubstantially vertical heel seam; and a portion of the void thatreceives the foot; wherein the sole structure includes a midsole and anoutsole, at least one of the first layer and the second layer extendingbetween the midsole and the outsole and at least one of the first layerand the second layer contacting the outsole, and the third layerextending over the midsole.
 31. The article of footwear recited in claim30, wherein the second layer is formed from a polymer material andmolded to the first layer.
 32. The article of footwear recited in claim30, wherein the first layer and the third layer are textile materials,and the polymer material of the second layer infiltrates the textilematerial of the first layer to secure the second layer to the firstlayer.
 33. The article of footwear recited in claim 30, wherein thethird layer is adhesively-joined with at least one of the first layerand the second layer.
 34. The article of footwear of claim 30, whereinthe third layer extends between the midsole and an insole.
 35. Thearticle of footwear of claim 34, wherein the third layer issubstantially in contact with the midsole and the insole.
 36. Thearticle of footwear of claim 30, wherein the third layer is joined withat least one of the first layer and the second layer along a side of theupper.
 37. The article of footwear of claim 30, wherein a size of one ormore openings in the mesh structure varies throughout the upper.
 38. Thearticle of footwear of claim 37, wherein the size of the one or moreopenings may be based on a desired degree of flexibility in a portion ofthe upper.
 39. The article of footwear of claim 30, wherein a thicknessof a segment of the mesh structure varies throughout the upper.
 40. Amethod of manufacturing an article of footwear having an upper and asole structure including a midsole and an outsole, the method comprisingsteps of: providing a first layer of an upper of the article offootwear; molding a second layer of the upper to the first layer, thesecond layer having a mesh structure with different properties indifferent portions of the upper; joining a third layer of the upper withat least one of the first layer and the second layer such that thesecond layer is positioned between the first layer and the third layer;and in a bottom region of the upper, separating the third layer from thefirst and second layers and extending the third layer over a top surfaceof the midsole; and extending the first and second layers over a bottomsurface of the midsole, at least one of the first and second layersbeing in contact with the outsole.
 41. The method recited in claim 40,wherein the step of providing includes selecting the first layer to be atextile.
 42. The method recited in claim 41, wherein the step of moldingincludes inducing a polymer material to infiltrate a portion of thefirst layer.
 43. The method recited in claim 40, further including astep of positioning the first layer to be an first layer of the articleof footwear, and positioning the third layer to be an third layer thatdefines avoid for receiving a foot.
 44. The method recited in claim 43,further including a step of joining edges of the third layer to formseams, and including a step of positioning an insole within the void,the insole being positioned between: each of the seams except asubstantially vertical heel seam; and a portion of the void thatreceives the foot.
 45. The method of claim 40, wherein the step ofjoining the third layer of the upper with at least one of the firstlayer and the second layer includes joining the third layer with atleast one of the first layer and the second layer along a side of theupper.
 46. The method of claim 40, wherein the second layer is formed ofmultiple materials to provide the different properties in the differentportions of the article of footwear.
 47. The article of footwear ofclaim 40, wherein the second layer is formed of a material havingdifferent densities in different regions to provide the differentproperties in the different portions of the article of footwear.